Part 2 of 2

The content of this article reflects changes called for in TSB 26-04-96.

SYNCHRONIZER OVERHAUL

DISASSEMBLY
Place synchronizer in a clean shop towel and wrap. Press on inner hub. Carefully open up shop towel and remove springs, balls, keys, hub, and sleeve.

CLEAN
Do not attempt to clean the blocking rings with solvent. The friction material will become contaminated. Place synchronizer components in a suitable holder and clean with solvent. Then dry them in air.




ASSEMBLY
1. Position synchronizer hub onto a suitable holding fixture (input shaft).
2. Install springs into hub slot
3. Insert key into hub and spring.




4. Apply petroleum jelly to the hole in the key. Insert balls into each key.




5. Slide sleeve over the hub and depress balls as you carefully slip the sleeve into position.




6. Line up stop ring tang over the keys in the hub. Install stop rings. Center the keys and balls by pushing on both stop rings.

INSPECT
Proper inspection of components involved:
- Teeth, for wear, scuffed, nicked, burred or broken teeth keys, for wear or distortion
- Balls and springs, for distortion, cracks or wear If any of these conditions exist in these components, replace as necessary.

SHIFTER RAILS OVERHAUL
1. Disassemble the transaxle case.
2. Remove shifter rails from the geartrain.
3. To service the SIR shift rail, remove the C-clip retaining the reverse shift lever arm. Remove the 5th shift fork roll pin and remove the 5th shift fork. Remove the shift lug roll pin and remove the shift lug. Replace parts as necessary.
4. To service the 3-4 shift rail, remove the roll pin retaining the 3-4 shift fork. Remove the shift fork. Remove the shift lug roll pin and remove shift lug. Replace parts as necessary.
5. To service the 1-2 shift rail, remove the roll pin retaining the 1-2 shift fork. Remove the shift fork and replace parts as necessary.

GEAR CASE OVERHAUL
The components that are left in the gear cases when the gear train is pulled out are the:
- Axle shaft seals
- Output bearing race and retainer
- Input bearing and sleeve
- Differential bearing cones
- Shifter rail bushings
- Shifter shafts
- Shifter shaft seals
- Shifter shaft bushings
- Rear bearing oil feed trough

AXLE SHAFT SEALS

REMOVAL




1. Insert a flat blade pry tool at outer edge of axle shaft seal.
2. Tap on the pry tool with a small hammer and remove axle shaft seal.

INSTALLATION




1. Clean axle shaft seal bore of any excess sealant.
2. Align axle shaft seal with axle shaft seal bore.
3. Install axle seal on tool # 6709 with C-4171 and insert into axle shaft seal bore.
4. Tap seal into position.

OUTPUT BEARING

REMOVAL




1. Remove caged roller bearing from output bearing race. Install bearing with large diameter cage facing outward.




2. Remove screws at output bearing retainer strap.




3. Install tool # 6787 and slide hammer C-3752. Tighten tool to output bearing race.

INSTALLATION




1. Line up output bearing race to race bore.

2. Insert tool # C-4628 with C-4171 into output bearing race. Tap race into bore. Install bearing with large diameter cage facing outward.

INPUT BEARING AND SLEEVE

NOTE: The input bearing is a bearing and sleeve one piece unit. The sleeve is the slide point for the clutch release bearing and lever.

REMOVAL




1. Install tool # 6342 over input bearing on the gear case side of the transaxle clutch housing.
2. Tap the input bearing out of the housing.

INSTALLATION




1. Position sleeve and bearing assembly at input bearing bore.
2. Install tool # C-4680-1 over input bearing.




3. Tap input bearing into bore until it is fully seated.

DIFFERENTIAL BEARING CUPS

REMOVAL




1. Remove differential assembly from gear case.
2. Install Miller tool # L451 8 into the differential bearing cup.




3. Install the tool cup over the tool.
4. Tighten the tool until the race is removed from the case.

INSTALLATION
1. Position the bearing cup into the case.
2. Install the bearing cup onto Miller tool # L-4520.
3. Using Miller tool # L-4520 and C-4171 driver, install differential bearing cup into the transaxle case.

SHIFTER RAIL BUSHINGS

REMOVAL




1. Thread tool # 6786 into shifter rail bushing.

2. Install slide hammer # C-3752 onto tool.

3. Remove bushing using slide hammer and tool assembly.

INSTALLATION

1. Line up replacement bushing in bore.
2. Using tool # MD998343, tap bushing into bore until flush with the chamfer in the case.

SHIFTER SHAFT SEALS

NOTE: It is not necessary to remove the shifter shafts from the transaxle to service the shifter shaft seals.

REMOVAL
1. Using a pick tool, pry up on the shifter shaft seal and remove seal from bore.

INSTALLATION
1. Position new shifter shaft seal in bore.
2. Install shifter shaft seal into bore using an appropriate size deep well socket.

SHIFTER SELECTOR SHAFT

REMOVAL
1. Disassemble transaxle.
2. With the transaxle disassembled, remove the selector shaft by pushing on the shaft from the outside and pulling shaft out from the inside.
3. Reverse removal procedure to install selector shaft.

SHIFTER CROSSOVER SHAFT

REMOVAL




1. Disassemble transaxle.
2. With the transaxle disassembled, remove the crossover shaft seal.
3. Use snap ring plier to remove the snap ring at the crossover shaft bore.
4. Push the crossover shaft in the case and remove the crossover assembly.
5. Reverse removal procedure to install crossover shaft.

SHIFTER SELECTOR SHAFT BUSHING REMOVAL




1. Remove selector shaft.
2. Thread tool # 6786 into bushing.
3. Install slide hammer # C-3752 onto tool and remove bushing using slide hammer.

INSTALLATION




1. Position replacement bushing over selector shaft bore.
2. Using an appropriate size deep well socket, install bushing in selector shaft bore.

SHIFTER CROSSOVER SHAFT BUSHING

REMOVAL




1. Install slide hammer # C-3752 through the crossover bushing.
2. Thread nut and washer onto slide hammer.
3. Using the slide hammer, remove the crossover shaft bushing.

INSTALLATION
1. Position the replacement crossover shaft bushing over the crossover shaft bushing bore.
2. Using an appropriate size deep well socket, install the crossover shaft bushing into the bushing bore.

REAR BEARING OIL FEED TROUGH

REMOVAL

NOTE: The bearing oil feed trough is retained in the case by a pin that is molded into the case and clips that are part of the trough.

1. Using light plier pressure, squeeze the clips together at the rear of the trough.
2. Slide the trough over the retaining pin that locates the trough in the case.
3. Reverse removal procedure to install oil feed trough.

INPUT SHAFT REASSEMBLY




1. Place input gear into shop press.
2. Install 3rd gear caged needle bearing on input shaft.




3. Install 3rd gear and 3-4 synchronizer onto input shaft. Install Special Tool # C-3717 over input shaft and press on synchronizer hub and 3rd gear. The synchronizer hub has the letter "U" stamped on the top face of the hub. This designates that the hub must be installed with the "U" facing upward.




4. Install 314 synchronizer snap ring into slot on input shaft.




5. Install blocking ring into 3-4 synchronizer. Install 4th gear caged needle bearing.




6. Install 4th gear onto input shaft.




7. Install 4-5 split thrust washer separation pin.




8. Install split thrust washer onto input shaft.




9. Install split thrust washer retaining ring.




1O. lnstall 5th gear caged needle bearing.




11. Using special tool # C-3717, install 5th speed gear and synchronizer. The 5th gear synchronizer hub has the letter "R" stamped on the top face of the hub. This designates that hub must be installed with the "R" facing upward.




12. Install 5th gear synchronizer snap ring.

CASE REASSEMBLY




1. Verify pallet shims are removed from pallet Install output and input gear into pallet fixture (Miller tool # 6785-3).




2. Install shift rails and forks into pallet fixture.




3. Install shifter shaft, shift finger and blocker assembly into pallet fixture.




4. Install reverse brake race onto input gear.




5. Install reverse brake needle bearing.




6. Install reverse brake blocking ring.




7. Install reverse brake friction cone.




8. Install reverse brake shim. Apply petroleum jelly to shim to hold in place.




9. Install gear case half over pallet fixture. Line up shift finger over 3-4 shift lug.




10. Line up reverse brake friction cone lug to the slots in the gear case. Verify reverse brake shim is in position.




11. Using Miller tool # C-4992-1 press on input and output shaft bearings until they bottom into the case and against the shafts.




12. lnstall shaft snap rings at input and output bearings.




13. Apply MOPAR RTV sealant to end cover outer edge and around bolt holes. Install end cover onto gear case. Tighten end cover bolts to 26 Nm (19 ft.lbs.).
14. Remove gear case from pallet fixture.
15. lnstall gear case in a holding fixture with and cover facing down.




16. Turn selector shaft into slot on blocker assembly.




17. Push selector shaft spacer clip onto selector shaft.




18. Install reverse idler gear and shaft. Install bolt into shaft Tighten bolt on shaft to 20 Nm (15 ft.lbs.) torque.








19. lnstall reverse fork bracket and reverse lockout. Tighten screws to 11 Nm (96 in. lbs.) torque.




20. lnstall differential into gear case.

DIFFERENTIAL BEARING PRELOAD ADJUSTMENT
1. Remove bearing cup and existing shim from clutch bellhousing case.
2. Press in new bearing cup into bellhousing case (or use a cup that has been ground down on the outer edge for ease of measurement).
3. Press in new bearing cup into gear case side.
4. Oil differential bearings with SAE 5W-30 engine oil and install differential assembly in transaxle gear case. Install clutch bellhousing over gear case. Install and torque case bolts to 26 Nm (19 ft.lbs.). Record end play.
5. Position transaxle with bellhousing facing down on workbench with C-clamps. Position dial indicator.
6. Apply a medium load to differential with Tool C-4995 and a T-Handle, in the downward direction. Roll differential assembly back and forth many times. This will settle the bearings. Zero dial indicator. To obtain end play readings, apply a medium load in the upward direction while rolling differential assembly back and forth. Record end play.
7. The shim required for proper bearing preload is total of end play and (constant) preload of 0.18 mm (0.0071 in.). Combine shim, if necessary, to obtain the required shim (see Shim Chart for proper shims).
8. Remove case bolts. Remove clutch bellhousing differential bearing cup. Install shim (s) selected in step (7). Then press the bearing cup into clutch bellhousing.
9. Apply a 1/16 inch bead of MOPAR Gasket Maker, Loctite 518, or equivalent to outer edge of case and around the bolt holes. Install clutch bellhousing. Install and torque case bolts to 26 Nm (19 ft.lbs.).
10. Using special tool C4995 and an inch-pound torque wrench, check turning torque of the differential assembly clockwise and counterclockwise. The turning torque should be 68 to 136 Nm (6 to 12 in.lbs). If the turning torque is too high, install a 0.05 mm (0.0020 in.) thinner shim. If the turning torque is too low, install a 0.05 mm (0.0020 in.) thicker shim.
11. Recheck turning torque. Repeat Step (10) until the proper turning torque is obtained.